Shear ram type blowout preventer with integral gas producing generator

ABSTRACT

An angle-cut shear ram blowout preventer system containing an angle-cut shear ram inside a ram housing with a ram housing bore with an integral gas producing generator. A ram cylinder pressure housing can be secured to the ram housing, wherein the ram cylinder pressure housing can be fluidly connected to a hydraulic pressure source or a pneumatic pressure source. A piston in the ram cylinder pressure housing can be fluidly connected to the hydraulic pressure source or the pneumatic pressure source. A taper can be extended from the ram housing bore into a through bore to simultaneously sever a pipe in a well and seal the well once the pipe is severed without requiring additional downhole tools.

CROSS REFERENCE TO RELATED APPLICATIONS

The current application is a Continuation in Part of co-pending U.S.patent application Ser. No. 15/241,311 filed on Aug. 19, 2016, entitled“SHEAR RAM TYPE BLOWOUT PREVENTER,” which is a Continuation in Part ofco-pending US patent application Ser. No. 14/571,774 filed on Dec. 16,2014, entitled “SHEAR RAM TYPE BLOWOUT PREVENTER,” now issued as U.S.Pat. No. 9,593,550 on Mar. 14, 2017, which claims priority to and thebenefit of U.S. Provisional Patent Application Ser. No. 61/964,436 filedon Jan. 6, 2014, entitled “ANGLE-CUT SHEAR-RAM TYPE BLOWOUT PREVENTER.”These references are herein incorporated in their entirety.

FIELD

The present embodiments generally relate to an improved blowoutpreventer with integral gas producing generator using a solid propellantproducing gas and in more particularly a new type blowout preventer(BOP) having one or more angled-cut shear rams so that in the event of awell blowout with pipe in the hole, and the ram piston activated, theangled ram blade with hardened serrations passes across the pipe in thebore, cutting into the pipe at a specific angle with one longpowerstroke at the same time a second angle lifts up on the pipe causing thepipe to snap and break. This new method is referred to herein as “TheScore and Break technique” rather than the old brute force blunt nosecrush and mash method customary with conventional BOPs.

BACKGROUND

Having absolute pressure control of a hydrocarbon producing well duringall drilling and completion operations is an absolute must. This is toprotect personnel first and then the drilling rig and other expensiveequipment. The main device in place for well pressure control duringthese operations is the blowout preventer (BOP). BOPs are designedeither as ram, ram-shear or annular BOPs and all are used to seal awellbore in the event of a blowout. Drilling for hydrocarbons involvespenetrating a variety of subsurface geological formations which arelayers in the earth. Each layer comprises a specific geologiccomposition such as, shale, sandstone, limestone, etc. The layers maycontain trapped fluids or gas at different formation pressures, and theformation pressures usually increase with increasing depth. The mudweight of the drilling fluid in the wellbore is made heavy enough withbarite etc. to overcome the formation pressure. This is done byincreasing the density of the drilling fluid in the wellbore or/andincreasing pump pressure at the surface of the well.

There are occasions during drilling operations when a wellbore maypenetrate a layer having a formation pressure substantially higher thanthe pressure maintained in the wellbore by the mud weight. When thisoccurs, the well is said to have taken what is called a kick. Thepressure increase associated with the kick is generally produced by gasalong with oil, and water or a combination of all of these, and ofcourse the mud is also kicked back with the influx of formation fluidsfrom within the wellbore. The high pressure kick propagates from a pointof entry in the wellbore up-hole from a high pressure region below to alow pressure region above. If the kick is allowed to reach the surface,drilling fluid, well tools, and other drilling tools may be blown out ofthe wellbore. These blowouts often result in catastrophic destruction ofthe drilling equipment including the drilling rig and could causesubstantial injury or death to rig personnel.

Because of the of the potential for blowouts, BOPs are either installedat the surface or on the sea floor in deep water drilling arrangementsso that kicks may be adequately controlled and circulated out of thesystem. BOPs may be activated to effectively seal in a wellbore untilmeasures can be taken to control the kick and as stated earlier thereare several types of BOPs, the most common of which are annular blowoutpreventers.

Annular blowout preventers typically comprise annular bulk elastomerdonut shaped seals that are forced radially inward to squeeze around thedrill pipe and/or running tools to completely seal the wellbore. Anothertype of blowout preventer is the ram-type blowout preventer. Ram-typepreventers comprise a body supporting at least two oppositely positionedcylinders on each side of the through bore with powerful pistonsinternally which actuate rams. The rams may be pipe rams or variablepipe rams which, when activated, move to engage and surround drill pipeand well tools to seal the wellbore. Shear rams which, when activated,move to engage and physically shear any drill pipe or well tools in thewellbore. The rams are located opposite of each other, and whether piperams or shear rams the rams are normally located against one another atthe center of the wellbore. In some cases, ram blocks are used whichwill effectively shear both rigid and flexible materials that arelocated in the through bore of the BOP.

Prior art of a couple of pipe ram assemblies are disclosed. A commoncharacteristic of these pipe ram and shear ram blowout preventers isthat each individual ram assembly comprises a carrier or holder of sometype and a ram block connected to the carrier for limited relativelateral movement. One advantage of the former kind of construction isthat each ram assembly comprises a relatively movable carrier and ramblock, and a seal may be installed between the carrier and ram block,and such seal may be compressively actuated by relative movement of thecarrier and ram block. More specifically, the ram assemblies are movedinwardly.

If the blowout preventer is of the pipe ram type, which simply sealsaround the outer diameter of the drill pipe, it is fairly convenient todesign the structure so that the thicknesses of the ram block andcarrier, measured longitudinally with respect to the drill pipe, aregenerally equal. This is desirable because it maximizes the surface areaover which the forces may be distributed.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description will be better understood in conjunction withthe accompanying drawings as follows:

FIG. 1 depicts a side view of the angle-cut shear ram blowout preventer(BOP) system according to one or more embodiments.

FIG. 2 depicts a cross section of the angle-cut shear ram blowoutpreventer (BOP) system according to one or more embodiments.

FIG. 3 depicts a cross section of the angle-cut shear ram prior toengagement with a pipe in the angle-cut shear ram blowout preventer(BOP) system according to one or more embodiments.

FIG. 4 depicts a cross section of the angle-cut shear ram fullyextending creating a seal in the through bore according to one or moreembodiments.

FIG. 5 depicts a cross section of the angle-cut shear ram creating astress score mark on the heavy wall drill pipe according to one or moreembodiments.

FIG. 6 depicts a cross section of the angle-cut shear ram after cuttingand lifting the heavy wall drill pipe in the through bore according toone or more embodiments.

FIG. 7 depicts an embodiment of the angle-cut shear ram with twonon-rotating rods according to one or more embodiments.

FIG. 8 depicts an embodiment of the angle-cut shear ram with two ramcylinder pressure housings connected together using a common rodaccording to one or more embodiments.

FIG. 9 depicts a remote monitoring system according to one or moreembodiments.

FIG. 10 presents an integral gas producing generator usable with one ormore embodiments.

The present embodiments are detailed below with reference to the listedFigures.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Before explaining the present apparatus in detail, it is to beunderstood that the apparatus is not limited to the particularembodiments and that it can be practiced or carried out in various ways.

The present embodiments pertain to novel, and new angle-cut shear ramtype blowout preventers to be placed and run in the blowout preventer(BOP) stack for the purpose of shearing tubing, pipe, heavy wall drillpipe, heavy drill collars or running tools in the event of a blowoutwhich could occur in many places in the formation of an oil or gas wellwhile the heavy wall drill pipe and/or tools are still in the hole.

This novel BOP comprises a housing having a through vertical bore andcan be adapted to be connected to and sealed to a wellhead, a riser orpart of a lower marine riser package, placed in alignment with thewellbore. The ram or rams are movable within guide-ways on either sideof the ram housing, across the through bore, moving from the fullyretracted position where the front cutting edge of the ram can be fullywithdrawn and the through bore can be fully open to the fully extendedposition where the cutting edge has moved across the through bore,cutting anything that might have been in the opening and sealing thethrough bore.

The angled-cut ram-blade can be made at 40 degrees across the leadingcutting edge, to be longer on one side and shorter on the other,resembling a 40 degree triangle with the lead cutting edge tapered atthe top away from the heavy wall drill pipe being cut so as to lift theweight of the heavy wall drill pipe while the heavy wall drill pipe isbeing cut, this is similar to pulling on a piece of steak, stretching itwhile cutting it with a serrated knife blade. The tapered ram blade canbe also serrated with hardened teeth. The ram blade can be thick enoughto seal and hold the full well pressure when blocking the through bore.

In this particular disclosure, there is only one angle-cut ram-bladewith one powerful piston extending from one side of the BOP housing.When the piston is activated, the angle-cut ram moves across the throughbore of the BOP. The angled and tapered leading edge of the angle-cutram-blade forces the opposite side of the heavy wall drill pipe overagainst the side of the BOP's though bore, pressing against a hardenedknife edge to retain the heavy wall drill pipe and helping to create astress riser in the heavy wall drill pipe to be cut on the opposite sideby the hardened serrated teeth of the ram.

The combined forces on both sides of the heavy wall drill pipe, plus therip in the heavy wall drill pipe from the serrated teeth on the shearram blade as it saws across the heavy wall drill pipe at an angle, alongwith the upward force caused by the taper on the leading edge of therams simultaneously sever a pipe in a well and seal the well once thepipe is severed without requiring additional downhole tools.

The present embodiments will now be described more fully herein withreference to the illustrated embodiments set forth herein; rather theseembodiments are provided so that this disclosure will be thorough andcomplete and will fully cover the scope of the invention to thoseskilled in the art. Like numbers refer to like elements throughout.Accompanying drawings in which embodiments of the invention are shown.This invention may, however, be embodied in many different forms andshould not be construed as limited to the following.

The embodiments are designed to assist eliminate catastrophic mechanicalequipment failure thus preventing death and dismemberment of rigpersonnel.

The embodiments are designed to prevent catastrophic mechanicalequipment failure that would otherwise cause environmental contaminationby containing biohazardous discharges.

The embodiments are designed to prevent catastrophic mechanicalequipment failure thus preventing equipment blowout that can cause firesand explosions at a location.

In embodiments, an integral gas producing generator be used as afail-safe option to support existing BOP safety measures.

The embodiments include an angle-cut shear ram blowout preventer (BOP)system to be used over a well when drilling for hydrocarbons throughsubterranean geological formations, during a blowout, the angle-cutshear ram blowout preventer (BOP) system can be configured tosimultaneously sever a heavy wall drill pipe in the well and seal thewell once the heavy wall drill pipe is severed without requiringadditional downhole tools, the angle-cut shear ram blowout preventer(BOP) system can be installed on a blowout protector housing having athrough bore, the through bore containing the heavy wall drill pipe, theheavy wall drill pipe extending between the well and a surface.

The angle-cut shear ram blowout preventer (BOP) system can have a ramhousing with a ram housing bore.

The ram housing can be secured to the blowout protector housing. The ramhousing bore intersects with a through bore.

In embodiments, a first ram cylinder pressure housing can be secured tothe ram housing.

A first piston can be contained in the first ram cylinder pressurehousing connected to a common rod longitudinally disposed in the firstram cylinder pressure housing. The first piston can be aligned with theram housing bore.

A second ram cylinder pressure housing can be secured to the first ramcylinder pressure housing. The second ram cylinder pressure housing canbe fluidly connected to the first ram cylinder pressure housing.

A second piston can be contained in the second ram cylinder pressurehousing.

The second piston can be longitudinally connected to the common rod. Thesecond piston can be fluidly connected to the hydraulic pressure sourceor the pneumatic pressure source. The common rod can be removable andcan be disposed, at least partially, within each ram cylinder pressurehousing. The common rod can be movable from a retracted position to anextended position in each ram housing bore.

At least one non-rotating rod can be disposed in the ram cylinderpressure housing.

An angle-cut shear ram can be connected to the common rod.

In embodiments, the angle-cut shear ram can have a body engaging thecommon rod and a taper with a cutting edge formed on the body oppositethe common rod.

The angle-cut shear ram can be adapted to extend the taper from the ramhousing bore into the through bore to sever heavy wall drill pipe aspressure is applied to the pistons from the hydraulic pressure source orthe pneumatic pressure source, and extend at least a portion of the bodyinto the through bore creating a through bore seal in the through borewith at least a portion of the body after the heavy wall drill pipe issevered by the taper.

Turning now to the Figures, FIG. 1 depicts a side view of the angle-cutshear ram blowout preventer (BOP) system according to one or moreembodiments with an integral gas producing generator. Details of theintegral gas producing generator are viewable in FIG. 10.

The angle-cut shear ram blowout preventer (BOP) system 100 can be usedover a well when drilling for hydrocarbons through subterraneangeological formations, during a blowout in order to simultaneously (i)sever a heavy wall drill pipe in a well and (ii) seal the well once theheavy wall drill pipe is severed without requiring additional downholetools.

The angle-cut shear ram blowout preventer (BOP) system 100 can beattached to the blowout protector housing 12.

Each angle-cut shear ram blowout preventer (BOP) system 100 can have aram housing 5.

In embodiments, a first ram cylinder pressure housing 21 a can besecured to the ram housing 5. The first ram cylinder pressure housing 21a can be fluidly connected to a hydraulic pressure source 101 or apneumatic pressure source 102.

A pressure containing end cap 24 can be on one end of the first ramcylinder pressure housing 21 a. The pressure containing end cap 24 canbe mounted, enabling easy access, maintenance and repair of the system.

In embodiments, an access flange 20 can be secured to the ram housing 5enabling easy access, maintenance and repair of the system. Studdedflanges 18 a through 18 h can secure the pressure containing end cap 24.In embodiments, studded flanges 18 i and 18 p can secure the accessflange 20. Two gaskets 19 a and 19 b can be used with the pressurecontaining end cap and access flanges respectively. Additional gasketscan be used on the top and the bottom of blowout protector housing 12for bolting in and sealing to the wellhead, riser and/or lower marineriser package.

The angle-cut shear ram blowout preventer (BOP) system 100 can includeat least one clamp 26 a and 26 b for engaging above and below theblowout protector housing 12, connecting, locking, and sealing theangle-cut shear ram blowout preventer (BOP) system 100 to the blowoutprotector housing 12.

FIG. 2 depicts a cross section of the angle-cut shear ram blowoutpreventer (BOP) system according to one or more embodiments.

The angle-cut shear ram blowout preventer (BOP) system 100 can have aram housing 5 with a ram housing bore 6. A first piston 22 a can bealigned with the ram housing bore 6. A center axis 104 for the ramhousing bore 6 is shown.

The hydraulic pressure source or the pneumatic pressure source can befluidly connected to and power the first piston 22 a in the first ramcylinder pressure housing 21 a. The psi can be very low to power thefirst piston 22 a; however, the psi must be enough to shear the heavywall drill pipe. The psi used can be affected by the wall thickness ofthe heavy wall drill pipe, whether or not the heavy wall drill pipe isheat treated, such as a psi from 500 psi to 10,000 psi.

In embodiments, the ram housing 5 can have an angle-cut shear ram 14,which can be connected to a common rod 23. The angle-cut shear ram 14can have two portions, namely a body 15 engaging the common rod 23 and ataper 29 formed on the body 15 opposite the common rod 23. The angle-cutshear ram 14 is shown in a retracted position.

The angle-cut shear ram 14 can be adapted to extend the taper 29 fromthe ram housing bore 6 into a through bore 13 to sever the heavy walldrill pipe as pressure is applied to the first piston 22 a from thepneumatic pressure source or the hydraulic pressure source. As thepressure extends at least a portion of the body 15 into the through bore13, the body 15 of the angle-cut shear ram 14 creates a through boreseal in the through bore 13 after the heavy wall drill pipe is severed.

In embodiments, as the angle-cut shear ram 14 severs the heavy walldrill pipe and then extends the taper 29 from the ram housing bore 6 aspressure is applied, causing each length of stroke of the first piston22 a to increase in length by a distance from 1 percent to 300 percentof a diameter of the through bore 13.

The angle-cut shear ram blowout preventer (BOP) system can include apressure divider 25 with a seal and bearing assembly for the common rod23.

The common rod 23 can be connected to the first piston 22 a. The commonrod 23 can be movable from a retracted position at least partiallywithin the first ram cylinder pressure housing 21 a into the ram housingbore 6 of the ram housing 5.

The ram housing bore 6 can be secured to the blowout protector housingand can intersect with the through bore 13, such as at a 90 degreeangle. The angle-cut shear ram blowout preventer (BOP) system 100 canfluidly communicate with the through bore 13.

Hardened shear reaction inserts 16 a and 16 b can be mounted in reliefrecesses to engage the heavy wall drill pipe. It should be understoodthat as the angle-cut shear ram 14 applies load to the heavy wall drillpipe, the taper 29 also applies a lifting force to the heavy wall drillpipe at a 90 degree angle to the load from the angle-cut shear ram 14while the hardened shear reaction inserts 16 a and 16 b hold the heavywall drill pipe down.

FIG. 3 depicts a cross section of the angle-cut shear ram prior toengagement with a pipe in the angle-cut shear ram blowout preventer(BOP) system according to one or more embodiments.

The ram housing 5 can be connected to the first ram cylinder pressurehousing 21 a. The first ram cylinder pressure housing 21 a can containthe first piston 22 a and the angle-cut shear ram 14 in the retractedposition. A cutting edge 31 of the angle-cut shear ram 14 can be at anangle on the taper 29, such as at a forty degree angle. A heavy walldrill pipe 28 is shown in the through bore.

The common rod 23 of the first piston 22 a can extend and retract alongthe center axis 104 of the angle-cut shear ram 14.

The angle-cut shear ram blowout preventer (BOP) system can have a tang27 connecting the common rod 23 to the body 15. The angle-cut shear ramblowout preventer (BOP) system can have hardened serrated teeth 91disposed on the cutting edge 31. The hardened serrated teeth 91 cansimultaneously (i) create a stress score mark while (ii) applying alifting force for parting the heavy wall drill pipe 28 without deformingthe hardened serrated teeth 91. The lifting force can range from 1,000psi to 500,000 psi. The lifting force in embodiments can raise the heavywall drill pipe 28 from 0.125 of an inch to 3 inches.

The access flange 20 is can be secured to the ram housing 5, and thepressure containing end cap 24 can be mounted to the first ram cylinderpressure housing 21 enabling easy access, maintenance and repair of theangle-cut shear ream blowout preventer (BOP) system.

In embodiments, as the cutting edge 31 contacts the heavy wall drillpipe 28 at an angle, such as a 40 degree angle, from the center axis 104in the horizontal plane and angles back at 40 degrees or less from thecenter axis 104 in the vertical plane, the cutting edge of the taper 29saws across the heavy wall drill pipe 28 at 40 degrees or less whilesimultaneously lifting the heavy wall drill pipe 28 at 40 degrees ormore.

FIG. 4 depicts a cross section of the angle-cut shear ram fullyextending creating a seal in the through bore according to one or moreembodiments.

In embodiments, the first piston 22 a and the angle-cut shear ram 14 canbe in an extended position along the center axis 104. The heavy walldrill pipe 28 in the through bore can be in a parted configuration, thatis, the heavy wall drill pipe 28 can be successfully severed by theangle-cut shear ram 14.

The ram housing 5 containing the common rod 23 of the first piston 22 acan be connected to the angle-cut shear ram 14 by the tang 27, which canbe similar to the way a gate valve can be connected to a valve stem.

The pressure divider 25 can be mounted between the through bore and theram housing 5. In embodiments, the pressure divider 25 can be mountedinside the first ram cylinder pressure housing 21 a without fasteners.

Multiple high strength carbide cutting nodes 200 a-200 p can beinstalled on the cutting edge 31 of the taper 29. The multiple highstrength carbide cutting nodes 200 a-200 p can be disposed on the taper29. In embodiments, a tungsten carbide hardened edge 93 can be disposedon the taper 29.

The multiple high strength carbide cutting nodes 200 a-200 p can be ofat least one of: a tungsten carbide insert, a synthetic diamond cuttingmaterial, a diamond enhanced cutting material, a diamond impregnatedmetal matrix, and combinations thereof.

In embodiments, if a diamond enhanced cutter material can be used, theinserts can be at least two rows of diamond cutter material on thecutting edge 31.

The multiple high strength carbide cutting nodes 200 a-200 p can be flatfaced, dome shaped, or combinations thereof. The poly-diamond cuttermaterial and the multiple high strength carbide cutting nodes 200 a-200p can have various shapes such as circular, elliptical, angular, orcombinations thereof.

In embodiments, the tungsten carbide hardened edge 93 can be disposed onthe cutting edge 31. In embodiments, the tungsten carbide hardened edge93 can be a crushed tungsten carbide in a nickel bronze matrix. Inembodiments, the tungsten carbide hardened edge 93 can be a plurality ofseparated tungsten carbide cutting segments formed in polygonal shapes.

The cutting materials, such as poly-diamond cutter nodes, can be groupedin circles, organized in swirl patterns, or in another pattern.

In embodiments, the density of the poly-diamond cutter nodes can rangefrom 0.125 inches to 2 inches. The poly-diamond cutter nodes can bealigned in rows of two poly-diamond cutter nodes to sixteen poly-diamondcutter nodes. In other embodiments, the poly-diamond cutter nodes can bealigned in rows, such as several nodes in rows of three.

In embodiments, the poly-diamond cutter nodes can be made from syntheticdiamond material made by US Synthetic of Orem, Utah. The poly-diamondcutter nodes can be flat faced, dome shaped, or combinations thereof.The poly-diamond cutter nodes can have a shape that is elliptical,circular, angular, or combinations thereof. The height of eachpoly-diamond cutter node as measured from the surface of one of thespiraled angled sections can range from flush flat to about ¾ of aninch.

The multiple high strength carbide cutting nodes 200 a-200 p can beformed on the spiral angled section, either as a single row, doublerows, triple rows, multiple rows, or in patches. The multiple highstrength carbide cutting nodes 200 a-200 p are known as “carbideinserts” in the industry. Usable high strength carbide cutting nodes canbe round, elliptical, or angular. Usable high strength carbide cuttingnodes can be flat faced or round faced.

The access flange 20 can be secured to the ram housing 5, and thepressure containing end cap 24 can be mounted to the first ram cylinderpressure housing 21 a enabling easy access, maintenance and repair ofthe angle-cut shear ram blowout preventer (BOP) system.

In embodiments, the cutting edge 31 of the angle-cut shear ram 14 cantravel at a 90 degree angle across the through bore engaging the heavywall drill pipe 28 at an angle offset from a center axis 104 of theangle-cut shear ram 14.

In embodiments, the angle-cut shear ram 14 can travel at a 90 degreeangle across the through bore engaging the heavy wall drill pipe at anangle offset from 2 degrees to 40 degrees from the center axis 104 ofthe angle-cut shear ram 14.

FIG. 5 depicts a cross section of the angle-cut shear ram creating astress score mark on the heavy wall drill pipe according to one or moreembodiments.

In embodiments, a section of the heavy wall drill pipe 28 can be a drillcollar. The heavy wall drill pipe 28 can be in the through bore 13 ofthe blowout protector housing. The first piston 22 a with the common rod23 a in the first ram cylinder pressure housing 21 a can drive theangle-cut shear ram 14 into the heavy wall drill pipe 28 against theside of the through bore 13 and against the hardened shear reactioninserts 16 a and 16 b located in relief recesses 17 a and 17 b.

As the angle-cut shear ram 14 applies load to the heavy wall drill pipe28, the taper 29 can also apply a lifting force to the heavy wall drillpipe 28 at a 90 degree angle to the load from the angle-cut shear ram 14while the hardened shear reaction inserts 16 a and 16 b hold the heavywall drill pipe 28 down. This pulling apart action plus the sawingaction of the cutting edge of angle-cut shear ram 14 can cause the heavywall drill pipe 28 to part.

The hardened shear reaction inserts 16 a and 16 b can grip and hold oneside of the heavy wall drill pipe 28 while the other side of the heavywall drill pipe 28 is being cut and lifted by the taper 29.

A stress score mark 59 can be formed circumferentially on the heavy walldrill pipe by the cutting edge as pressure is applied to the firstpiston 22 a.

FIG. 6 depicts a cross section of the angle-cut shear ram after cuttingand lifting the heavy wall drill pipe in the through bore according toone or more embodiments.

The first ram cylinder pressure housing 21 a with the first piston 22 ais shown pushing against the angle-cut shear ram 14 in the ram housing5.

The angle-cut shear ram 14 is shown fully engaged across the throughbore 13 of blowout protector housing and connected against the accessflange 20 with the heavy wall drill pipe 28 fully parted.

The upper part of the heavy wall drill pipe 28 is lifted and can beresting on top of the angle-cut shear ram 14. The angle-cut shear ram 14can form a metal seal across the through bore 13 of the blowoutprotector housing.

In embodiments as the angle-cut shear ram blowout preventer (BOP) systemcan move the angle-cut shear ram 14 from a retracted position in the ramhousing bore into the through bore 13, the angle-cut shear ram 14 canexert a load on the heavy wall drill pipe 28 in the through bore 13rotating the heavy wall drill pipe 28 in the through bore 13 whilesimultaneously applying: (i) a circumferential sawing action on theheavy wall drill pipe creating the stress score mark 59 on the heavywall drill pipe 28 while the heavy wall drill pipe 28 rotates in thethrough bore 13. The angle-cut shear ram 14 can simultaneously with thecircumferential sawing action apply (ii) a lifting force at the formedstress score mark 59 causing the heavy wall drill pipe 28 to separate.

In embodiments, the angle-cut shear ram blowout preventer (BOP) systemcan have a sliding ram track 55 mounted in the ram housing bore engagingthe taper as the taper moves from a retracted location in the ramhousing bore into the through bore 13. In embodiments, two rails can beused in parallel to align the angle-cut shear ram. In other embodiments,the sliding ram track 55 can be integral in the ram housing bore.

FIG. 7 depicts an embodiment of the angle-cut shear ram with twonon-rotating rods according to one or more embodiments.

The ram housing 5 can be connected to first ram cylinder pressurehousing 21 a with an external non rotating rod 56 a and an internal nonrotating rod 56 b extending through the first ram cylinder pressurehousing 21 a on either side of the common rod 23. The non-rotating rodscan be in parallel to the center axis. Each non-rotating rod can havedifferent diameters from each other. The diameters of the non-rotatingrods are dependent on a given bore and pressure of the system. Forexample, a pair of non-rotating rods can range in size from 1 inch to 8inches. In embodiments, the non-rotating rods can be formed from steel,such as high strength steel.

Hardened shear reaction inserts 16 a and 16 b can be mounted in reliefrecesses 17 a and 17 b to engage the heavy wall drill pipe 28. It shouldbe understood that as the angle-cut shear ram 14 in the ram housing bore6 applies load to the heavy wall drill pipe 28 in the through bore 13,the taper 29 also applies a lifting force to the heavy wall drill pipe28 at a 90 degree angle to the load from the angle-cut shear ram 14while the hardened shear reaction inserts 16 a and 16 b hold the heavywall drill pipe down.

The stress score mark 59 can be formed circumferentially on the heavywall drill pipe 28 by the cutting edge as pressure is applied to thefirst piston 22 a.

FIG. 8 depicts an embodiment of the angle-cut shear ram with two ramcylinder pressure housings connected together using a common rodaccording to one or more embodiments.

In embodiments, the ram housing 5 can be secured to the blowoutprotector housing. In embodiments, an access flange 20 can be secured tothe ram housing 5.

The first ram cylinder pressure housing 21 a can be secured to the ramhousing 5, wherein the first piston 22 a in the first ram cylinderpressure housing 21 a can be connected to the common rod 23, which canbe longitudinally disposed in the first ram cylinder pressure housing 21a. The first piston 22 a can be aligned with the ram housing bore,wherein the ram housing bore can have the center axis 104.

A second ram cylinder pressure housing 21 b can be secured to the firstram cylinder pressure housing 21 a, wherein the second ram cylinderpressure housing can be fluidly connected to the first ram cylinderpressure housing.

In embodiments, a non-rotating rod 56 can extend through the second ramcylinder pressure housing 21 b.

A pressure containing end cap 24 can be mounted to the second ramcylinder pressure housing 21 b.

In embodiments, a second piston 22 b can be mounted in the second ramcylinder pressure housing 21 b. The second piston 22 b can belongitudinally connected to the common rod 23.

The second piston can be fluidly connected to the hydraulic pressuresource 101 or the pneumatic pressure source 102.

A hydraulic pressure source 101, a pneumatic pressure source 102 orcombinations thereof can be used to move the first piston 22 a and thesecond piston 22 b via extend ports 30 a and 30 b or retract ports 32 aand 32 b.

The common rod 23 can be disposed, at least partially, within each ramcylinder pressure housing 21 a and 21 b, the common rod 23 can bemovable from a retracted position to an extended position in the ramhousing bore.

The tang 27 can be used for connecting the common rod 23 to the body 15.

In embodiments, the angle-cut shear ram 14 can be connected to thecommon rod 23.

A hollow bore 88 can be formed in the common rod 23. In embodiments, alinear displacement transducer 89 can be disposed in the hollow bore 88enabling remote control of the common rod 23.

In embodiments, the heavy wall drill pipe 28 can be in the through bore13. The heavy wall drill pipe 28 can extend between a well and asurface. The well can flow hydrocarbons or drilling fluids from the wellto the surface.

In embodiments, wherein the second ram cylinder pressure housing 21 b isconnected or mounted to the first ram cylinder pressure housing 21 a,the pressure containing end cap 24 can be mounted to the second ramcylinder pressure housing 21 b without mounting to the first ramcylinder pressure housing.

FIG. 9 depicts a remote monitoring system according to one or moreembodiments.

A network 606 can be connected the linear displacement transducer 89 forcommunicating with a client device 666.

The client device can be any known client device in the industry, suchas a computer, a laptop, a tablet computer, a mobile or cellular phone,or any device that is capable of bidirectional communication.

FIG. 10 presents an integral gas producing generator 302 usable with oneor more embodiments.

The integral gas producing generator 302 can be mounted to the pressurecontaining end cap 24 with a gas inlet port 301. The pressure containingend cap 24 can be mounted to the first ram cylinder pressure housing 21a, which can have the first piston 22 a.

In embodiments, the gas inlet port 301 can be formed through thepressure containing end cap 24, and the integral gas producing generator302 can be fluidly connected to the gas inlet port 301 and fixedlymounted to the pressure containing end cap 24.

The integral gas producing generator 302 can have a tubular body 304affixed to and extending axially from the pressure containing end cap 24while in fluid communication with the gas inlet port 301.

The integral gas producing generator 302 can operate similar to thosemanufactured by Bastion Technologies, Inc., of Houston, Tex.

In embodiments, the tubular body 304 can contain a third piston 42movably disposed in a generator housing bore 41. The third piston 42 canhave an ignition end 309 and a pressurization end 310.

A propellant chamber 312 can be formed on the ignition end 309 of thethird piston 42 opposite the pressurization end 310.

A pressurized fluid chamber 314 can be located on the pressurization end310 of the third piston 42 for supplying pressurized fluid 316 into thegas inlet port 301 of the pressure containing end cap 24.

The pressurized fluid 316 can be exhausted under pressure into the gasinlet port 301 in response to ignition of a propellant charge 320contained in the propellant chamber. The pressurized fluid can have apressure ranging from 5,000 psi to 20,000 psi.

A one-way flow control device 322 can be connected to the pressurecontaining end cap 24 permitting one-way flow from the pressurized fluidchamber 314 to the shear ram blowout preventer (BOP) system to enableon/off operation of the integral gas producing generator 302 into theshear ram type blowout preventer (BOP) system.

The integral gas producing generator provides a fail/safe mechanism toprevent offshore drilling rig explosion incidents from happening.

The integral gas producing generator stops death on an oil rig.

While these embodiments have been described with emphasis on theembodiments, it should be understood that within the scope of theappended claims, the embodiments might be practiced other than asspecifically described herein.

What is claimed is:
 1. An angle-cut shear ram blowout preventer systemto be used over a well when drilling for hydrocarbons throughsubterranean geological formations, during a blowout, the angle-cutshear ram blowout preventer system is configured to simultaneously severa heavy wall drill pipe in the well and seal the well once the heavywall drill pipe is severed without requiring additional downhole tools,the angle-cut shear ram blowout preventer system is installed on ablowout protector housing having a through bore, the through borecontaining the heavy wall drill pipe, the heavy wall drill pipeextending between the well and a surface, the angle-cut shear ramblowout preventer system comprising: a. a ram housing with a ram housingbore, wherein the ram housing is secured to the blowout protectorhousing, and wherein the ram housing bore intersects with the throughbore; b. a first ram cylinder pressure housing secured to the ramhousing; c. a first piston in the first ram cylinder pressure housingconnected to a common rod, the common rod disposed in the first ramcylinder pressure housing, wherein the first piston is aligned with theram housing bore; d. a second ram cylinder pressure housing secured tothe first ram cylinder pressure housing, wherein the second ram cylinderpressure housing is fluidly connected to the first ram cylinder pressurehousing; e. a second piston in the second ram cylinder pressure housing,wherein the second piston is longitudinally connected to the common rod;f. a generator housing with integral gas producing generator having agenerator housing bore, and a third piston positioned in the generatorhousing bore, wherein the generator housing is secured to the blowoutprotector housing, wherein the third piston is aligned with the ramhousing bore and longitudinally connects to the common rod; wherein thefirst piston, the second piston, the third piston or combinations of thefirst, second and third pistons are fluidly connected to a hydraulicpressure source or a pneumatic pressure source, and wherein the commonrod is disposed, at least partially within the first ram cylinderpressure housing, the second ram cylinder pressure housing, thegenerator housing, or combinations of the first ram cylinder pressurehousing, the second ram cylinder pressure housing, and the generatorhousing, with the common rod moveable from a retracted position to anextended position in the ram housing bore; g. at least one non-rotatingrod disposed in the first ram cylinder pressure housing, the second ramcylinder pressure housing, the generator housing or combinations of thefirst ram cylinder pressure housing, the second ram cylinder pressurehousing and the generator housing; and h. an angle-cut shear ramconnected to the common rod, wherein the angle-cut shear ram comprises:(i) a body engaging the common rod; and (ii) a taper with a cutting edgeformed on the body opposite the common rod; and wherein the angle-cutshear ram is adapted to extend the taper from the ram housing bore intothe through bore to sever the heavy wall drill pipe as pressure isapplied sequentially using the first piston, then adding the secondpiston and finally adding the third piston, from the hydraulic pressuresource or the pneumatic pressure source, and extend at least a portionof the body into the through bore creating a through bore seal in thethrough bore with at least the portion of the body after the heavy walldrill pipe is severed by the taper.
 2. The angle-cut shear ram blowoutpreventer system of claim 1, wherein the angle-cut shear ram isconfigured to move from a retracted position in the ram housing borethrough the through bore exerting a load on the heavy wall drill pipe inthe through bore rotating the heavy wall drill pipe in the through borewhile simultaneously applying: (i) a circumferential sawing action onthe heavy wall drill pipe creating a stress score mark on the heavy walldrill pipe while the heavy wall drill pipe rotates in the through bore,and (ii) a lifting force at the formed stress score mark causing theheavy wall drill pipe to separate.
 3. The angle-cut shear ram blowoutpreventer system of claim 2, further comprising hardened serrated teethdisposed on the cutting edge, wherein the hardened serrated teethsimultaneously create the stress score mark and apply the lifting forcefor parting the heavy wall drill pipe without deforming.
 4. Theangle-cut shear ram blowout preventer system of claim 3, wherein thecutting edge of the angle-cut shear ram travels at a 90 degree angleacross the through bore engaging the heavy wall drill pipe at an angleoffset from a center axis of the angle-cut shear ram.
 5. The angle-cutshear ram blowout preventer system of claim 4, wherein the angle-cutshear ram travels at a 90 degree angle across the through bore engagingthe heavy wall drill pipe at an angle offset from 2 degrees to 40degrees from the center axis of the angle-cut shear ram.
 6. Theangle-cut shear ram blowout preventer system of claim 4, wherein as thecutting edge engages the heavy wall drill pipe at 40 degrees from thecenter axis in a horizontal plane and angles back at 40 degrees or lessfrom the center axis in a vertical plane, the cutting edge of the tapersaws across the heavy wall drill pipe at 40 degrees or less whilesimultaneously lifting the heavy wall drill pipe at 40 degrees or more.7. The angle-cut shear ram blowout preventer system of claim 4, whereinas the angle-cut shear ram severs the heavy wall drill pipe and thenextends the taper from the ram housing bore as the pressure is applied,causing each length of stroke of the piston to increase in length by adistance from 1 percent to 300 percent of a diameter of the throughbore.
 8. The angle-cut shear ram blowout preventer system of claim 6,further comprising a plurality of hardened shear reaction inserts togrip and hold one side of the heavy wall drill pipe while an oppositeside of the heavy wall drill pipe is being cut and lifted by the taper.9. The angle-cut shear ram blowout preventer system of claim 8, furthercomprising a clamp for engaging above and below the blowout protectorhousing connecting, locking, and sealing the angle-cut shear ram blowoutpreventer system to the blowout protector housing.
 10. The angle-cutshear ram blowout preventer system of claim 1, further comprising a tangfor connecting the common rod to the body.
 11. The angle-cut shear ramblowout preventer system of claim 1, further comprising an access flangesecured to the ram housing enabling easy access, maintenance, and repairof the angle-cut shear ram blowout preventer system, and a pressurecontaining end cap mounted to the ram cylinder pressure housing enablingeasy access, maintenance, and repair of the angle-cut shear ram blowoutpreventer system.
 12. The angle-cut shear ram blowout preventer systemof claim 1, further comprising a pressure divider mounted between thethrough bore and the ram housing.
 13. The angle-cut shear ram blowoutpreventer system of claim 12, wherein the pressure divider is mountedinside the ram cylinder pressure housing without fasteners.
 14. Theangle-cut shear ram blowout preventer system of claim 1, furthercomprising a sliding ram track mounted in the ram housing bore engagingthe taper as the taper moves from a retracted location in the ramhousing bore into the through bore.
 15. The angle-cut shear ram blowoutpreventer system of claim 14, wherein the sliding ram track is integralin the ram housing bore.
 16. The angle-cut shear ram blowout preventersystem of claim 1, further comprising at least one multiple highstrength carbide cutting node disposed on the taper.
 17. The angle-cutshear ram blowout preventer system of claim 16, wherein the at least onehigh strength carbide cutting node is comprised of at least one of: atungsten carbide insert, a synthetic diamond cutting material, a diamondenhanced cutting material, a diamond impregnated metal matrixes, andcombinations thereof.
 18. The angle-cut shear ram blowout preventersystem of claim 1, further comprising a tungsten carbide hardened edgedisposed on the taper.
 19. The angle-cut shear ram blowout preventersystem of claim 1, further comprising two rails positioned substantiallyparallel to each other to align the angle-cut shear ram.
 20. Theangle-cut shear ram blowout preventer system of claim 1, furthercomprising a hollow bore formed in the common rod and a lineardisplacement transducer disposed in the hollow bore enabling remotecontrol of the common rod.
 21. The angle-cut shear ram blowout preventersystem of claim 1, further comprising a gas inlet port formed throughthe pressure containing end cap, and the integral gas producinggenerator producing gas fluidly to gas inlet port and wherein theintegral gas producing generator is fixedly mounted to the pressurecontaining end cap.